Method of making electromagnetic impulse motors



H. E, UPHAM Dec. 5, 19440 METHOD OF MAKING AN ELECTRO-MAGNETIG IMPULSE MOTOR Original Filed Oct. 17, 1942 Harry E. Upham Patented Dec. 5, 1944 METHOD OF MAKING ELECTROMAGNETIC IMPULSE MOTORS Harry E. Upham, Bridgeport, Conn., assignor to Remington Rand Inc., Buffalo, N. Y., a corporation of Delaware Original application October 1'7, 1942, Serial No. 462,383. Divided and this application May 22, 1943, Serial No. 488,051

3 Claims.

This invention relates to method of making an electro-magnetic impulse motor of the make and break'contact type, such as used in electric dry shavers, and particularly to improvements in the rotor mounting and rotor shaft structure.

This application is a division of application Serial No. 462,383 filed October 1'7, 1942.

The invention is directed to improving the rotor mounting structure in a way that will facilitate the manufacture of the parts and eliminate the use of specially skilled labor in the assembly and adjustment of the parts so as to reduce the cost of manufacture to a considerable extent.

The invention comprehends the provision of a rotor assembly structure wherein the contact operating cam can be formed on the end of the rotor shaft in a convenient manner with the elimination of expensive machining operations and with the production of the shafts in a uniform manner so they are interchangeable with one another and the other parts of the motor with which they are associated.

The invention provides for the assembly of the rotor on the rotor shaft in a fixed radial position relative to the shaft in order that the required angular relation between the poles of the rotor and the major axis of the contact operating cam can be obtained in the assembly of the motor in a simple manner without the use of special gauges in order that the rotor and contact operating cam will be arranged so that the contacts of the motor are made and broken at the desired points in the rotation of the rotor to secure the most efiicient operation of the motor.

The invention contains a number of other features involved in the structure and assembly of the rotor and the rotor shaft with itsvarious parts that will be apparent from the following specific description of the structure and the claims.

In the drawing:

Fig. 1 shows a side elevation of the contact 'carrying side of an electro-magnetic impulse motor in which the scale of the motor as illustrated is substantially enlarged.

Fig. 2 is a fragmentary transverse cross section through the upper portion of the motor as shown in Fig. 1 substantially enlarged from the showing in Fig. 1, illustrating the rotor assembly structure in cross section, the section extending axially along the rotor shaft.

Fig. 3 is a section taken transversely to the rotor shaft, on a scale of the size indicated in Fig. 1, showing how the rotor is held in a predetermined radial position on the rotor shaft.

Fig. 4 shows the rotor shaft and the parts assembled thereon with the exception of the rotor in perspective and disassembled relation.

Fig. 5 is a side elevation of the opposite side of the starting wheel from that shown in Fig. 4.

The motor has a stator frame I carrying a field winding 2. Frame l is of substantial U- shape as illustrated in Fig. 1 having the free ends of the legs forming the U-shape frame providing the stator poles. Frame l is preferably constructed of laminated magnetizable metal of a character well-known in the art. The structure of stator frame I as illustrated in Fig. l, is well-known in the art and is incorporated in shaver motors now in commercial use. The free ends or poles of stator frame I have a pair of insulating plate members 3 and 4 respectively, se-

cured to the opposite side faces thereof in spaced parallel relation by means of suitable bolts 5.

A contact structure indicated generally at 6 in Fig. 1 is mounted on insulating plate 3. Contact structure 6 is of conventional form and has a pair of contact arms I. each carryinga contact point 8 at one end and each having a spring arm extension 9 extending from the other end and connected to a supporting bracket 10 suitably secured by rivets or the like to insulating plate 3. This contact structure is of a conventional type now well-known in the art and is connected in circuit in series with field winding 2. Bearing pads of suitable insulating material are indicated at ll and are adapted to be engaged by the contact operating cam to break engagement of points 8 in the conventional manner. The usual condenser shunted across the contact points is indicated at A2.

Insulating plates 3 and 4 are provided with rotor bearings I3 arranged in axially aligned relation and suitably riveted permanently in position in plates 3 and 4.

The invention is particularly directed to the construction and assembly of the rotor shaft, the rotor, the contact operating cam, the eccentric and the starting wheel, and adjustment of these parts in their assembled relation in bearings 13. This structure will now be described.

A rotor shaft l4 has opposite end portions rotatably mounted in bearings l3.- The left-hand end of shaft 14, as illustrated in Fig. 2, has areduced extension i5 and a contact operating cam l6 formed at the outer end thereof. The end of the shaft M including extension l5 and cam [6 has an axial bore extending inwardly from the end as indicated at H.

In making shaft M a piece of shaft stock has the bore II drilled therein and is machined out to provide the reduced extension I5 between the cam and the end of shaft I4. The cam I6 is then formed on the end of the shaft by die stamping through the use of suitably shaped dies to form the elliptical shape of the cam wherein the tubular metal structure at the end of the shaft is deformed from the cylindrical form of the stock into the elliptical form as illustrated in Figs. 1, 2 and 4 in order to provide the contact operating cam l6. Bore I1 provides space into which the metal in the end of the shaft is displaced in formin said cam. This die forming of the cams can be done by a cold die stamping operation and will accurately produce the elliptical cam for the efficient operation of contacts 8 in the desired timed relation to secure efficient motor operation. It will be noted that in the forming of the polygonal or elliptical cam, the bore I'I in the end of the shaft is also deformed in its shape by the metal being forced into the space provided by said bore to reduce its size and shape and that it is substantially elliptical in conformance with the elliptical shape of the outer surface forming cam I6.

The opposite end of rotor shaft i 4 is formed with a reduced cylindrical extension I8 terminating in another reduced threaded extension I9. A shoulder is formed at by the reduced extension I8.

An eccentric 2| is formed with a bore 22 to slidably engage and accurately fit on extension I8 so that one end of eccentric 2| will engage against shoulder 20 in the assembled relation of the eccentric on rotor shaft I4. Bore 22 in eccentrio 2| has one end thereof reduced and threaded in order to threadedly engage 0n the threaded extension I9 in the manner illustrated in Fig. 2

' so that eccentric 2| can be threaded onto extensions I8 and I9 to firmly and rigidly engage against shoulder 20 where eccentric 2| is firmly held in position against rotation relative to rotor shaft I4 in the operation of the motor.

A starting wheel 25 has a metallic supporting plate 26 formed with a central opening 21 to engage over the threaded reduced extension I9 on shaft I4. This plate 26 is embedded in suitable molded material indicated at 28 forming the outer covering and completing the wheel structure so as to provide a circular recess 29 on one side concentric to the opening 21 in plate 26. The side of starting wheel 25 formed with recess 29 has the margin thereof formed with a plurality of grooves and ribs indicated at 30 which is the portion that normally is exposed at the outside of a shaver through a suitable opening in the shaver case so as to provide for manual engagement with starting wheel 25 for starting the motor. The inner face of the covering 28 on starting wheel 25 is formed with an elliptical recess adjacent plate 26 as indicated at 3| in Fig. 4. Recess 3| is formed to receive one end of eccentric 2| in either of two positions when the starting wheel is assembled with eccentric 2| on the reduced extensions I8 and I9 of rotor shaft I4.

A roller 32 of insulating material of suitable character has a central aperture to receive the outer periphery of eccentric 2| for mounting and free rotation on eccentric 2| in the position shown in Fig. 2. Spacing and thrust bearing washer 33 is assembled on shaft I4 adjacent to eccentric 2|, is of larger'size than eccentric 2| and retains roller 32 on eccentric 2| when the motor shaft is assembled in the motor by reason of its engagement between eccentric 2| and the end of the right hand bearing I3 carried by insulating plate 4 as shown in Fig. 2. This thrust bearing washer 33 also acts to absorb the wear in the end-wise or axial motion of shaft I4 in bearings I3.

A spacing washer 34 is engaged on eccentric 2| between roller 32 and starting wheel 25 so as to compensate for wear in the rotation of roller 32 on eccentric 2|. Retaining nut 35 is screw threaded on the reduced threaded extension IS in the manner shown in Fig. 2. Nut 35 engages in opening 29 in starting wheel 25 against plate 26 so as to secure it firmly against one end of eccentric 2| which in turn is firmly seated against shoulder 20. When nut 35 is turned tightly to retain starting Wheel 25 against the end of cam 2|, the cam and the starting wheel are firmly secured on extensions I8 and I9 of the rotor shaft I4 against relative movement. Washers 33 and 34 and roller 32 are loosely positioned on the shaft in their assembled relation when the shaft is ready for assembly into bearings I3 before completing the motor structure.

The central portion of rotor shaft I4 is formed with a flat elongated section 36 forming a rotor locating means on the shaft. The rotor 31 is formed of laminated magnetizable material preferably having the laminations rigidly secured together by suitable rivets indicated in sections at 38 in Fig. 3. A two pole rotor is shown to correspond with the two pole stator. This rotor is formed in the central portion with, a rotor shaft receiving bore 39 while the outer periphery of rotor 31 is concentric to the axis of bore 39. This rotor structure is of substantially conventional form.

A screw 40 threaded in the central portion of one side of the rotor between the ends thereof forms a rotor positioning and locating means. This set screw 40 has a fiat end 4| constructed for engagement with fiat portion 36 forming the locating means on shaft I4 so that when screw 40 is threaded inwardly so that flat end 4| will have firm engagement with positioning face 38 on shaft I4, rotor 31 is arranged in a fixed radial relation with respect to shaft I4 and cam I6. Cam I6 usually has the major axis thereof arranged at an angle of approximately 7 to the center line through the poles of rotor 31 in order to secure the proper relation between the cam and the rotor for the efficient operation of the motor. This angular relation is indicated by the dot and dash lines in Fig. 1 at 42.

In making rotor shaft I4 the locating face 36 is provided thereon in advance of forming the cam I6 as hereinabove described. This locating face 36 is used to control the radial position of shaft I4 during the formation of the cam so that cam I6 has the major axis of the ellipse forming the outer surface at the angular relation indicated by the numeral 42 in Fig. 1.

Then, in assembly of the rotor structure on the motor shaft I4, the end of the rotor shaft formed with cam I6 is inserted through bearing I3 in plate 4 after the eccentric and starting wheel together with washers 33 and 34 and roller 32 have been assembled thereon. Rotor 3! is positioned between plates 3 and 4 with bore 39 aligned with bearing I3 in plate 4 so that the end of shaft I4 maybe inserted through shaft receiving bore 39 and through bearing I3 in the insulating plate 3. At the time of this assembly a thrust bearing washer 43, shown in Fig. 2, is engaged between bearing I3 in insulating plate 4 and rotor 31.

position is obtained, the shaft is adjusted to take up end play at the end carrying eccentric 32 and starting wheel 25. Rotor 3'! is moved toward eccentric 2| on shaft l4 so that practically all of the space at the ends of bearing l3 in plate 4 is taken up and thrust bearing washers 33 and 43 engage the ends of bearings l3 in plate 4. At this point the tightening of set screw 40 on face 36 will assemble the rotor and rotor shaft in the proper operative position to obtain emcient operation of the motor.

The freeness of rotation must be tried after the set screw is tightened so that in adjusting the rotor on shaft l4 a binding action is not created between thrust washers 33 and 43 and the ends of bearing l3 in plate 4. If there is binding then screw 40 should be loosened and a slight adjustment made, to allow a slight clearance between thrust washers 33 and 43 and bearing 13 so that just sufficient clearance is provided to allow free rotation of shaft l4 and rotor 31, but to prevent unnecessaryend play during the operation of the motor. When the rotor and rotor shaftare assembled in this manner contact operating cam l6 willbe positioned between cam engaging plates l I carried by the contact arms I so that the make and break between contacts 8 will be properly.

timed with respect to the rotor ,in the rotation thereof in operating the motor.

It will be seen from this construction and as-' sembly that uniformity'in the manufacture of parts is obtained in whichieach of the parts of the rotor shaft structure and assembly with the rotor are interchangeable so that worn parts can be replaced. The attachment of the rotor 31,

to shaft M in assembled relation is also used to obtain proper adjustment of the entire structure assembled on rotor shaft 14 in efficient operative position with rotor 31 secured at the proper angle relative to cam IS without the use of gauges. Special adjustments are not required because screw 40 forms a cooperative locating means in engagement with locating face 36 on shaft l4 to automatically locate rotor'3l in the proper position with respect to cam Hi. This enables the assembly of the entire rotor shaft structure and rotor in the motorin an efficient manner, rapidly and without the use of specially skilled labor, or special instruments or tools to make the assembly and proper adjustment of the rotor for free rotation in the bearings.

Cam roller 32 is adapted to engage a suitabl operating lever, not shown, that is customarily used when a motor of this type is used in a dry shaver so that in the operation of roller 32 with eccentric 2| the rotary movement of the rotor shaft l4 may be transformed into reciprocating motion by the lever which roller 32 is constructed to engage in order to secure the operation of the shaver in a manner well-known in the art. Roller 32 and eccentric 2| may be used in any desired manner to transmit the power of the motor for producing the desired motion of the mechanism with which the motor maybe associated in providing the source of driving power.

By forming rotor shaft l4 with the reduced extensions at both ends and positioning face 36 it will be seen that the shaft can be readily made in automatic machines and the positioning face 36 used to accurately locate and hold shaft I4 in position during the cold forming operation of cam IS. The dimension of the cam at the major axis thereof is not greater than the diameter of shaft l4. This provides not only for the economic manufacture of the shaft but also for the convenient assembly of the parts on the opposite end thereof as above described so that the end formed with cam I6 can be readily inserted through bearings l3 and shaft receiving bore 39 in rotor 31 in the assembly operation of the rotor on the shaft. A substantial saving in the cost of manufacture of motors is obtained through a construction and assembly of the parts as herein described.

It is to be further noted that by having one end of eccentric 2| engaged in recess 3| formed to snugly receive the eccentric in the starting wheel, relative movement of the eccentric and starting wheel in assembled relation will not This removes direct strain on the extension I9 of shaft I4 in starting the motor particularly because the direct engagement of the starting wheel with the eccentric will directly drive the mechanism operated by the eccentric.

The contact operating cam is described as polygonal or elliptical but it is to be understood that this cam does not have to be in the form of a true ellipse but may be of any desired shape of the character well-known in the art for the purpose in view of which the term elliptical will comprehend these variations in structure.

Further, in making this cam the bore and reduced section of the shaft may be formed simultaneously or either in advance of the other in manufacture and the claims will be understood to include this interpretation.

The invention claimed is:

l. The method of making a rotor shaft for small electric motors which comprises forming an axial bore in a portion of one end of a solid cylindrical metal shaft of small diameter, removing a segment from the central portion of said shaft to form a flat positioning'face, and deforming said end portion partially into the space formed by said bore while using said positioning face in holding said shaft in a predetermined position to form an external elliptical contact operating cam surface thereon having a major axis of a length not exceeding the shaft diameter in predetermined angular relation to said positioning face.

2. The method of making a rotor shaft for small electro-magnetic impulse motors which comprises forming a portion of one end of a solid cylindrical metal shaft of small diameter with an axial bore and a section of reduced diameter over the inner end of said bore, removing a segment of said shaft in the central portion to form a positioning face, and deforming said shaft at the end between said reduced section and the shaft extremity to provide an outer elliptical surface on said end while holding said shaft in fixed relation with said positioning face whereby said elliptical surface will have the major axis in predeter.. mined radial relation to said face and said axial bore provides space into which the metal in said shaft end is deformed in providing said outer elliptical surface to form an integral contact operating cam.

3. The method of making a rotor shaft for small electric motors which comprises axially drilling a portion of the length of a small diameter cylindrical metal shaft atone end to form a longitudinal bore, turning said shaft to remove an outer peripheral portion over the inner end of said drilled portion to provide a section of reduced diameter, removing a segment from the central portion of said shaft to provide a fiat positioning face thereon, deforming the end portion of said shaft between said reduced section and the extremity thereof while held in position by said positioning face to form a polygonal outer surface thereon in predetermined relation to said positioning face, and forming the opposite end of said shaft to provide a reduced cylindrical threaded extension and a shoulder at a predetermined distance from said positioning face, whereby a rotor may be adjusted longitudinally on the central portion of said shaft into a desired position relative to an eccentric mounted on said reduced extension in fixed relation to said shoulder while said positioning face positions said rotor radially on said shaft in predetermined angular relation to said polygonal outer surface forming a contact operating cam.

HARRY E. UPHAM. 

